Hazardous Location Engines Lebw0003-05

APPLICATION AND INSTALLATION GUIDE
HAZARDOUS LOCATION
ENGINES
Petroleum Hazardous Location Engines

• C9 (P9L, C9Y)
• C7 (C7P, P7L)
• C15 (HAZ)
• C32 (B2C)
Contents
1 Introduction and Purpose ........................................................................... 7
2 Important Safety Information ...................................................................... 7
3 Hazardous Location Terms and Compliance .................................................. 9
3.1 Cat® Hazardous Location Engine Compliance ........................................ 9
4 Engine Markings ..................................................................................... 14
4.1 ATEX Electrical Markings .................................................................. 14
4.2 ATEX Mechanical Markings .............................................................. 15
4.3 NEC 500 Markings .......................................................................... 15
4.4 NEC 505 Markings .......................................................................... 16
4.5 CE Marking ..................................................................................... 16
5 Ratings .................................................................................................. 17
5.1 Derated Engine Ratings .................................................................... 17
5.2 Non-Derated Engine Ratings .............................................................. 17
5.3 Constant Speed Ratings ................................................................... 18
6 Servicing Considerations .......................................................................... 18
6.1 Connecting Service Tools ................................................................. 19
6.2 Electrical Harness Connectors ........................................................... 19
6.3 Battery Disconnect .......................................................................... 21
7 Customer Installation Considerations ......................................................... 22
7.1 Wiring Requirements ........................................................................ 22
7.2 Cooling System ............................................................................... 34
7.3 Ambient Temperature Sensor (Derating C7 and C9) ............................. 35
7.4 Flame Proof Engine .......................................................................... 36
7.5 Exhaust Gas Cooler ......................................................................... 38
7.6 Altitude .......................................................................................... 43
8 ATEX Certified Attachments .................................................................... 43
8.1 Customer Supplied Attachments ....................................................... 43
8.2 Caterpillar Supplied Optional Attachments .......................................... 43
9 Engine Documentation ............................................................................. 50
9.1 EU Declaration of Incorporation ......................................................... 50
9.2 EU Declaration of Conformity ............................................................ 50
Foreword
This section of the Application and Installation Guide generally describes
hazardous location engines for Cat engines listed on the cover of this section.
Additional engine systems, components and dynamics are addressed in other
sections of this Application and Installation Guide.
Engine-specific information and data are available from a variety of sources. Refer
to the Introduction section of this guide for additional references. Contact the
Application Support Center (ASC) for the latest information on future Hazardous
location feature release dates.
Systems and components described in this guide may not be available or
applicable for every engine.
CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow,” the “Power

Edge” trade dress as well as corporate and product identity used herein, are
trademarks of Caterpillar and may not be used without permission.
Information contained in this publication may be considered confidential.
Discretion is recommended when distributing. Materials and specifications
are subject to change without notice.
The information in this document is the property of Caterpillar Inc. and/or its
subsidiaries. Without written permission, any copying, transmission to
others, and any use except that for which it is loaned is prohibited
©2014 Caterpillar
All Rights Reserved
Application and Installation Guide Hazardous Location Engines
Hazardous Location Engines

1 Introduction and Purpose
This document is intended to provide the necessary information for correct
installation of the following Cat Petroleum Hazardous Location Engines as used in
off-highway applications: C7, C9, C15 and C32.
The information in this document is the property of Caterpillar Inc. and/or its
subsidiaries. Without written permission, any copying, transmission to others, and
any use except that for which it is loaned is prohibited.
Contact the Application Support Center (ASC) for the latest information on future
Hazardous location feature release dates.
2 Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused
by failure to observe basic safety rules or precautions. An accident can often be
avoided by recognizing potentially hazardous situations before an accident occurs.
A person must be alert to potential hazards. This person should also have the
necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be
dangerous and could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product,
until you have read and understood the operation, lubrication, maintenance, and
repair information.
Safety precautions and warnings are provided in this manual and on the product.
If these hazard warnings are not heeded, bodily injury or death could occur to you
or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal
Word” such as “DANGER”, “WARNING” or “CAUTION”. The Safety Alert
“WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be
either written or pictorially presented.
©2014 Caterpillar
All Rights Reserved Page 7
Hazardous Location Engines Application and Installation Guide
Operations that may cause product damage are identified by “NOTICE” labels on
the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a
potential hazard. The warnings in this publication and on the product are, therefore,
not all inclusive. If a tool, procedure, work method or operating technique that is
not specifically recommended by Caterpillar is used, you must satisfy yourself that
it is safe for you and for others. You should also ensure that the product will not be
damaged or be made unsafe by the operation, lubrication, maintenance or repair
procedures that you choose.
The information, specifications, and illustrations in this publication are on the
basis of information that was available at the time that the publication was written.
The specifications, torques, pressures, measurements, adjustments, illustrations,
and other items can change at any time. These changes can affect the service that
is given to the product. Obtain the complete and most current information before
you start any job. Cat dealers have the most current information available.
©2014 Caterpillar
Page 8 All Rights Reserved
3 Hazardous Location Terms and Compliance

3.1 Cat® Hazardous Location Engine Compliance
Cat Petroleum Hazardous Location Engines are certified for use in Class I Division
2 (NEC 500), Class I Zone 2 (NEC 505), and ATEX Directive (94/9/EC) Group II, 3G
environments (Zone 2).
The mechanical system of these engines meets the following ratings:
Ambient = -XX°C < Ta < +XX°C (Rating Specific)
Zone = 2 (3G)
Gas Group = IIA (only ATEX applies for mech. system)
Temperature Class = T3
The electrical system meets the following ratings:

Ingress Protection = IP56
Ambient = -XX°C < Ta < +XX°C (Rating Specific)
Zone = 2 (3G)
Gas Group = IIC (ATEX and NEC 505); ABCD (NEC 500)
Temperature Class = T3
3.1.1 Class I Division 2 / Zone 2

Class I Division 2 and Class I Zone 2 are in reference to the North American
standard that addresses the engine’s electrical system only. Cat Petroleum
Hazardous Location Engines are assessed and certified by Factory Mutual (FM) or
Intertek to meet this standard.
The standard places equipment into three basic categories: Class I, Class II, and
Class III. Class I is for equipment in environments containing flammable gases,
vapors, or liquids. Cat Petroleum Hazardous Location Engines are Class I. Class II is
defined for combustible dusts, and Class III for combustible fibers. Neither Class II
nor Class III apply to the Cat products in this guide and are not covered.
A general description of a Class I Division 2 (NEC 500) area is one where
flammable gases, flammable liquid-produced vapors, or combustible liquid-produced
vapors are handled, processed, or used. However, this is an area where the
existence of such gases or vapors is not a normal occurrence and would be the
result of the accidental failure of a container or ventilation equipment that would
otherwise prevent the existence of ignitable concentrations of such gases or
vapors. A specific definition of a Class I Division 2 zone should be referenced from
the NEC standard.
©2014 Caterpillar
A Class I Division 1 area is one where these same ignitable concentrations of

such gases or vapors may exist under normal operating conditions. This is a higher
classification than the engines currently offered and discussed in this guide. At the
time of this publication, Caterpillar does not offer any Petroleum Class 1 Division 1
certified engines.
Class I Zone 2 (NEC 505) terminology is very similar to the Class I Division 2
classification, except that when using the “Zone X” terminology, Division 1
equipment can be further divided into Zone 0 and Zone 1 equipment. As such,
Class I Division 2 and Class I Zone 2 terminology indicate the same location
classification. See Table 3.1 below.
North American Area Classifications

Division Zone
Class Description
(NEC 500) (NEC 505)
A zone where ignitable
concentrations of
flammable gases,
vapors, or liquids are
Zone 0
present continuously or
for long periods of time
under normal operating
Division 1 conditions
concentrations of
flammable gases,
Class I
Zone 1 vapors, or liquids are
likely to exist under
normal operating
conditions
concentrations of
flammable gases,
Division 2 Zone 2 vapors, or liquids are
not likely to exist under
normal operating
conditions.
Shaded area represents Cat Hazardous Location Engine Compliance.
Table 3.1
©2014 Caterpillar
3.1.1.1 NEC 500 and NEC 505 Gas Groups

The NEC 500 and NEC 505 gas groups are divided by the type of explosive gas,
liquid, or vapor that may be present in the environment.
3.1.1.1.1 NEC 500
Cat Petroleum Hazardous Location Engines comply with all of the NEC 500 gas
groups up to T3 temperature class. Below is a description of typical gases found in
gas groups, A, B, C, and D.
Group A: Acetylene
Group B: Hydrogen
Group C: Coal gas (lighting gas) or Ethylene.
Group D: Acetone, Ethane, Ethyl ethanoate, Ammonia, Benzol (pure), Ethanoic
acid, Carbon oxide, Methane, Methanol, Propane, Toluene, Ethanol, i-
Amyl acetate, n-Butane, n-Butyl alcohol, Benzene, Diesel fuel, Aircraft
fuel, Heating oils, n-Hexane.
3.1.1.1.2 NEC 505
Cat Petroleum Hazardous Location Engines comply with all of the NEC 505 gas
groups up to T3 temperature class. Below is a description of typical gases found in
gas groups, IIA, IIB, IIB + Hydrogen, and IIC.
IIA (same as Group D from NEC 500): Acetone, Ethane, Ethyl ethanoate,
Ammonia, Benzol (pure), Ethanoic acid, Carbon oxide, Methane, Methanol,
Propane, Toluene, Ethanol, i-Amyl acetate, n-Butane, n-Butyl alcohol,
Benzene, Diesel fuel, Aircraft fuel, Heating oils, n-Hexane.
IIB (same as Group C from NEC 500): Coal gas (lighting gas) or ethylene.
IIB + Hydrogen (same as Group B from NEC 500): Ethylene and/or Hydrogen.
IIC (same as Group A from NEC 500): Acetylene.
3.1.2 ATEX Directive Compliance

The ATEX directive is a European standard that considers both electrical and
mechanical hazards. Cat Petroleum Hazardous Location Engines are assessed and
certified by third parties to meet this directive.
ATEX compliance is comprised of several different categories. Cat Petroleum
Hazardous Location Engines are certified for ATEX Directive 94/9/EC Equipment
Group II, 3G (Zone 2) environments with Gas Group IIA, and Temperature Class
T3.
©2014 Caterpillar
3.1.2.1 Group II, 3G (Zone 2) Environments

The ATEX directive is comprised of two machinery groups, Group I and Group II.
Group I is for mining equipment and is not covered in this guide. Any hazardous
location equipment that is not used for mining (Group I) is classified under Group II.
A description of Group II can be seen in Table 3.2.
ATEX Group II
Equipment Equipment Zone

Environmental Conditions
Group Category
Gas Dust
Explosive atmospheric conditions
1 0 20 always present, or present for
long periods of time.
Explosive atmospheric conditions
2 1 21 are likely to occur during normal
Group II
operation.
Explosive atmosphere is not likely
to occur during normal operation,
3 2 22
or will occur infrequently and for
short time periods.
Shaded area Applicable to Cat Hazardous Location Engines.
Table 3.2
As is the case in the North American region, equipment Categories (and Zones) in
Europe are divided by how frequently or likely an explosive atmospheric condition
will exist.
The terms 3G and Zone 2 are synonymous. The letter indicates the type of
explosive environment. “G” indicates a gaseous environment (gases, vapors, or
liquids) and “D” indicates dust. Using the terminology Zone 2 automatically defines
the piece of equipment as Category 3 for environments with potentially explosive
gases, vapors, or liquids.
3.1.2.2 ATEX Gas Groups
Flammable gases, vapors, and liquids are separated into three different groups.
Groups IIA, IIB, and IIC. Typical gases found in these groups include:
Group IIA: Acetone, ammonia, ethyl alcohol, gasoline, methane, and propane.
Group IIB: Acetaldehyde and ethylene.
Group IIC: Acetylene and hydrogen.
©2014 Caterpillar
3.1.2.3 Temperature Classes

The temperature class is the maximum temperature any surface of the piece of
equipment can reach. This is an important rating because different substances have
different temperatures at which they become autoignitable. Table 3.3 shows the
temperature classes of both the North American and European standards.
Temperature Classes
Class I Division 1, 2 ATEX
Temp. Class Temp. Limit Temp. Class Temp. Limit
T1 ≤ 450 °C T1 ≤ 450 °C
T2 ≤ 300 °C T2 ≤ 300 °C
T2A ≤ 280 °C N/A
T2B ≤ 260 °C N/A
T2C ≤ 230 °C N/A
T2D ≤ 215 °C N/A
T3 ≤ 200 °C T3 ≤ 200 °C
T3A ≤ 180 °C N/A
T3B ≤ 165 °C N/A
T3C ≤ 160 °C N/A
T4 ≤ 135 °C T4 ≤ 135 °C
T4A ≤ 120 °C N/A
T5 ≤ 100 °C T5 ≤ 100 °C
T6 ≤ 85 °C T6 ≤ 85 °C
Shaded area represents Cat Hazardous Location Engine Compliance.
Table 3.3
©2014 Caterpillar
4 Engine Markings
Each Cat Petroleum Hazardous Location Engine is affixed with certification plates
that indicate the protection concepts and equipment category of the engine.
4.1 ATEX Electrical Markings

The ATEX electrical certification plate may contain the following markings:
Classification: Ex nA nR ic IIC T3
Equipment Category: II 3G
Ambient Capability: Ta = XX°C
These markings can be defined as:

Ex: Specific marking to indicate explosion protection (ATEX only)
II: Equipment group (see section 3.1.2.1)
3G: Equipment category and atmosphere type (see section 3.1.2.1)
IIC: Gas group compliance (see section 3.1.2.2)
T3: Temperature rating (see section 3.1.2.3)
nA: Protection concept – No arcs, sparks, or hot surfaces (EN/IEC 60079-15
Standard)
nR: Protection concept – Restricted breathing to control flammable gases
(EN/IEC 60079-15 standard)
ic: Protection concept – Intrinsic safety for Zone 2 to limit the energy of sparks
and hot surfaces (EN/IEC 60079-11 Standard)
Ta: Ambient capability of electrical certification (see engine-specific
documentation on PowerNet)
©2014 Caterpillar
4.2 ATEX Mechanical Markings

The ATEX mechanical markings on the engine may contain:
Equipment Category: Ex II 3G
Gas Group: IIA
Temperature Class: T3

Ex: Specific marking to indicate explosion protection (ATEX only)
II: Equipment group (see section 3.1.2.1)
3G: Equipment category and atmosphere type (see section 3.1.2.1)
IIA: Gas group compliance (see section 3.1.2.2)
Ta: Ambient capability of mechanical certification (see engine-specific
documentation on PowerNet)
T3: Temperature rating (see section 3.1.2.3)
4.3 NEC 500 Markings

The NEC 500 markings may be seen as follows:
Classification: Class I Division 2 Groups ABCD

Protection Method: Non-Incendive Field Wiring (NIFW)
Ratings: 12/24 Vdc @ 15 Amperes

Class I Division 2: Equipment classification (see section 3.1.1)
Groups ABCD: NEC 500 Gas Groups (see section 3.1.1.1)
Non-Incendive: Non-incendive wiring protection (FM 3611 and ANSI/ISA
12.12.01 standards)
Ta: Ambient temperature rating for electrical system (See engine-
specific documentation on PowerNet)
Ratings: 12/24 Vdc @ 15 Amperes: Electrical system power rating
(See section 7.1.1)
©2014 Caterpillar
4.4 NEC 505 Markings

The NEC 505 markings may be seen as follows:
Classification: Class I Zone 2 Group IIC

Protection Method: nA nR ic
Ratings: 12/24 Vdc @ 15 Amperes

Class I Zone 2: Equipment classification (see section 3.1.1)
Group IIC: NEC 505 Gas group compliance (see section 3.1.1.1.2)
Ta: Ambient temperature rating for electrical system (See engine-
specific documentation on PowerNet)
nA: Protection Concept – No arcs, sparks, or hot surfaces
nR: Protection Concept – Restricted breathing
ic: Protection Concept – Intrinsic safety for Zone 2
Ratings: 12/24 VDC @ 15 Amperes: Electrical system power rating
(See section 7.1.1)
4.5 CE Marking
The CE mark is required per the ATEX directive 94/9/EC as part of the conformity
assessment procedures for products placed in the European Union (EU). The mark
indicates the product conforms to the provisions of the relevant Directives i.e.
ATEX and Electromagnetic Compatibility. The marking will typically be found in the
vicinity of the engine information labels. The CE marking will appear as depicted
below.
Note: The C15 Petroleum Hazardous Location engines do not bear
the CE mark because the electrical and mechanical systems
of these engines were certified as “components.” Per the
ATEX directive, “components” should not bear the CE mark.
C7, C9, and C32 Hazardous Location engines were certified
as “equipment” and bear the CE mark as described above. These are
simply differences in the certification process for each engine and should
not impact a customer’s ability to assess and certify their overall
package.
Declaration of Incorporation and Declaration of Conformity documentation
necessary for CE marking is available for every Petroleum hazardous location
engine. See Section 9 of this guide for further information.
©2014 Caterpillar
5 Ratings
5.1 Derated Engine Ratings
A derated hazardous location engine will automatically derate maximum available
engine power based on ambient conditions. Derating engine power is necessary to
maintain skin temperature and/or charge air temperature below the T3 temperature
classification.
Derate curves of available power at increasing ambient temperatures are available
in TMI for each derated rating. Maximum ambient temperature compliance for each
engine can be found on PowerNet in the pricelist, and on the engine certification
plate.
Note: Derated engine ratings require the customer to install an ambient
temperature sensor. More information and installation considerations are
found in section 7.3 of this guide.
300
250
200
Power, kW
150
100
Power at Lab Conditions

50
Derated Power @ 100 deg F, Sea Level
0
400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600
Speed, RPM
Figure 5.1
Example of Derate Rating Power Curve (C9)
5.2 Non-Derated Engine Ratings

A non-derated engine always follows the standard published performance curve
found in TMI. These engines will only maintain skin temperature and charge air
temperature compliance up to a specified maximum ambient temperature that will
be lower than that of the derated engine. Maximum ambient temperature
capabilities can be found on PowerNet in the pricelist, and on the engine
certification plate.
For applications that require the full power of a non-derated engine but are
required to operate at a higher ambient than the rating is capable of, it is possible
©2014 Caterpillar
to work with a 3rd party packager to increase the ambient capability by installing
additional components and/or technology.
5.3 Constant Speed Ratings

Some Hazardous Location engines may be available with constant speed ratings.
These ratings have been developed to meet emissions and hazardous location
requirements for applications where the engine operates at a single, constant
speed.
Engines rated for constant speed use are allowed to complete a starting
sequence, an operation at a single constant speed, and a shutdown sequence.
Every time the engine is run, each of these operations should occur only once. The
starting sequence and shutdown sequence can include a short period of operation
at the low idle speed for purposes of warming up and cooling down the engine or
driven equipment. The emissions type approval is not valid for operation of a
constant speed engine in a manner different from that described above.
An Idle/Rated Speed switch should be wired to the customer harness pin J1-45.
This switch should be CLOSED before starting and stopping the engine. When the
switch is CLOSED, the engine will operate at the low idle speed. When the switch
is OPEN, the engine will accelerate to the rated constant speed and the engine
speed control governor will maintain this engine speed.
6 Servicing Considerations
All servicing of hazardous location engines must be done by a

qualified technician familiar with hazardous locations. Failure to
heed this warning can lead to premature failures, product damage,
personal injury or death.
Exact part numbers must be used when servicing. Not utilizing exact
part numbers bears the risk of voiding hazardous location
certifications. Failure to heed this warning can lead to premature
failures, product damage, personal injury or death.
©2014 Caterpillar
6.1 Connecting Service Tools

Service tools need to be connected by using a “Y” connector or a “T” harness
and never by probing.
Probing into the harness is NOT allowed. Probing into the harness
renders it non-compliant to Hazardous Location directives and also
reduces the ingress protection – creating a potential hazard.
Warranty claims associated to harness probing are not honored.
Failure to heed this warning can lead to premature failures, product
damage, personal injury or death.
Any of the following “T” harness assemblies are acceptable in lieu of probing into
the harness:
 125-3662  257-8718
 208-0059  326-4904
 224-9282
Note: Ensure all maintenance is performed under a suitable permit to work
scheme and/or other locally accepted hazardous location safety practices.
Note: Cat service tools and the above harness assemblies are NOT compliant to
hazardous location directives. Appropriate precautions should be taken
when servicing with any non-hazardous location certified diagnostic
equipment while in a hazardous area.
6.2 Electrical Harness Connectors

6.2.1 C7, C9, and C32 Connectors
The electrical connectors on the engine harnesses of C7, C9, and C32 hazardous
location engines are specially designed to meet ATEX directives by requiring the
use of a tool to break the connection. The customer connection harnesses for use
with the C9 and C32 engines have auxiliary sensor pigtails which are certified as
intrinsically safe and do not require this style of connector, but instead use ampseal
connectors as used on the C15 (see below).
In order to disconnect the special electrical connectors, a tool is required to insert
into the release hole. See Figure 6.1 below.
©2014 Caterpillar
Note: Any tool that fits into the hole on this connector is suitable to use;
however, a tool without a sharp tip is recommended so as to not damage
the connector.
To disconnect electrical connections (Figure 6.1):
1) Push connectors together to release internal latching forces.
2) Insert tool into latch release hole.
3) Pull connector apart.
6.2.2 C15 Connectors Figure 6.1

The electrical connectors on C15 Hazardous Location engines are designed to
meet ATEX standards with a different protection concept. C15 engines use the
Intrinsic Safety protection concept.
Intrinsically safe circuits can use any standard wiring method; therefore, electrical
connectors on C15 Hazardous Location engines mechanically latch to prevent
inadvertent disconnection, but do not require a tool to disconnect. Refer to Figure
6.2.
©2014 Caterpillar
C15 Ampseal connector Figure 6.2
6.3 Battery Disconnect

A battery power disconnect should be incorporated to cut all battery power.
No harnesses or electrical connections should be connected OR

disconnected prior to cutting all battery power. Failure to heed this
warning can lead to premature failures, product damage, personal
injury or death.
See section 4.6 of the Electronics Application and Installation Guide, LEBH4623,
for specifics on the installation of a battery disconnect switch.
©2014 Caterpillar
7 Customer Installation Considerations

7.1 Wiring Requirements
Cat Petroleum Hazardous Location Engines have several additional wiring
requirements in order to comply with current hazardous location standards. These
are items that will be required by the customer in any hazardous location
installation.
The wiring harness and associated parts must be installed on the engine to
minimize mechanical and thermal stresses. These parts have been designed to
withstand normal engine lubricants and fuels. Special care must be taken by the
end user to ensure the harness and associated parts are not subject to attack by
aggressive substances on the non-metallic parts that could possibly compromise
their integrity.
7.1.1 Battery Circuit Protection
Hazardous location engines require additional circuit protection in addition to the
Caterpillar recommendation for non-hazardous location engines. An additional 15A
breaker for all un-switched battery (+) must be used in addition to the 10A breaker
on each individual input. See Figure 7.1 below, a modified diagram from the
Electronics A&I Guide (LEBH4623) which shows the 15A circuit breaker addition.
P1/J1 ECU
48 Un-switched Battery (+)

10 A
10 A
10 A
10 A
70 Switched Battery (+)
Key Switch
61 Un-switched Battery (-)
15 A
Engine
Chassis
Battery Master
Battery Disconnect Switch
Figure 7.1
Wiring and Circuit Protection for Hazardous Location Engines
©2014 Caterpillar
7.1.2 Termination of J1 harness

The hazardous location certification provided by Caterpillar for the electrical
system ends prior to the required customer supplied junction box. The J1 harness,
supplied by Caterpillar, does not include gas tight seals which may be required at
each conduit end for a given application. It is the customer’s responsibility to
properly terminate the pigtailed wiring at the customer end of the J1 harness.
Steps must be taken to ensure the wiring installation meets the site’s local
hazardous location directives and is appropriate for the application.
Wiring considerations include, but are not limited to (see Figure 7.2, Figure 7.3,
and Figure 7.4):
 Gas tight seals in the cabling between safe and hazardous zones
 Liquid tight conduits between safe and hazardous zones
 Approved junction box
 Separation of incendive and non-incendive circuits
 Fault current wire
Customer Interface
Engine Chassis Connection
Packager Supplied
Junction Box:
Liquid Tight
Connectors
Terminal Rail –
Incendive Wiring
Control Harness
Connection
Isolation Shield
ECM
Terminal Rail –
Non-Incendive
Wiring
Gas Tight Seal Required
Liquid Tight
Conduit Gas Tight Seal Required
Liquid Tight Conduit
HAZARDOUS AREA SAFE AREA
Customer Interface Wiring Zone 2 and Safe Zone

Figure 7.2
©2014 Caterpillar
Customer Interface
Engine Chassis Connection
Packager Supplied
Junction Box
Terminal Rail –
Control Harness Incendive Wiring

Connection
Isolation Shield
ECM
Terminal Rail –
Non-Incendive Wiring
Liquid Tight Liquid Tight

Conduit Connectors
Liquid Tight Conduit
HAZARDOUS AREA
Customer Interface Wiring Zone 2 Only

Figure 7.3
Bulkhead plate
70 pin bolted to ECM
connection guard
to the ECM
1-1/4” liquid-
tight conduit
Non-incendive Fault Current
Circuits Wire attached
(monitoring & with tie wraps.
diagnostics)
Incendive
Supplied in Interface Kit: Circuits (mainly
Gas Tight Seal
• Harness (25 foot) battery power)
• Conduit Gas Tight Seal
• Fittings
• Fault Wire
Customer Interface Kit Figure 7.4
Note: The C7, C9, C15 and C32 Customer Interface wiring includes a conduit
for both the incendive and non-incendive looms. This change went into
©2014 Caterpillar
effect during the second half of 2012, and product shipped prior to this
time will have different components included.
As noted in Figure 7.4, the customer interface kit for each engine includes the J1
harness (customer interconnect harness), 39 feet of conduit, a set of conduit
connectors, and 48 feet of fault wire. Additional miscellaneous pieces of hardware
are also included in certain kits. The harness part numbers for each engine are
shown below:
Engine Model J1 Harness P/N
C7 328-4129
C9, C15, C32 367-9759
7.1.3 Auxiliary Sensors and Jumper Harnesses (C9, C15 and C32)
The following optional auxiliary sensors are available on the C9, C15 and C32
Hazardous Location engines:
Note: The C9 and C32 hazardous location engines did not have this option at
introduction. The auxiliary pressure sensor is not compatible with older
versions of the customer interconnect harness. A new harness is available
that is compatible with the aux pressure sensor. Refer to SIS for more
information.
 Coolant Level Sensor
 Auxiliary Temperature Sensor – High Temperature Capability for monitoring
exhaust gas temperature as required by ATEX Standards
 Auxiliary Pressure Sensor
These sensors and the associated circuits of the J1 Customer Interface in the
ECM have been certified as Intrinsically Safe for Zone 2 Hazardous Locations.
Combined with the optional certified jumper harnesses, these sensors can be
connected to the pigtail connections on the Certified Customer Harness shown in
Figure 7.5.
©2014 Caterpillar
Figure 7.5
Note: The pigtail connections for the optional auxiliary sensors can be tie
strapped to the top of the ECM cover as shown in Figure 7.5.
7.1.3.1 Coolant Level Sensor

7.1.3.1.1 Coolant Level Monitoring Operation
The coolant level will be monitored if an optional coolant level sensor is installed.
Coolant level is monitored to automatically protect the engine when the coolant
level drops below a fixed level determined by the location of the sensor in the
cooling system. The coolant level is checked for each ECU action level configured
in the monitoring system for coolant level monitoring. If the coolant level is below
the minimum coolant level specified for the specified action level delay time, then
the ECU takes the appropriate action to respond to the fault condition. The engine
must be running at least 60 seconds before any fault condition is triggered. Once
©2014 Caterpillar
the fault is detected, the ECU illuminates the warning and diagnostic lamps and
logs the appropriate event code from the following table for the action taken:
Cat ET Description J1939 Description Status SPN FMI

Warning 111 17
Low Coolant Level Coolant Level Derate 111 18
Shutdown 111 01
The ECU can respond to the low coolant level condition with any or all of the
following actions: Warning, Derate, and Shutdown. The ECU logs an event code
and illuminates the lamps for all action levels. The ECU will respond with the
following additional actions when the monitoring system is configured to Derate or
Shutdown:
 Derate: Engine power is reduced to 35 percent below rated power over
two seconds (at a rate of 17.5 percent/second).
 Shutdown: The engine will shut down immediately.
7.1.3.1.2 Coolant Level Monitoring Configuration

Two parameters can be configured in Cat ET to customize the monitoring system
for coolant level monitoring.
1. ECU action for an event code defaults to “On” for Warning and Derate and
“Off” for Shutdown. All actions can be configured to “On” or “Off.”
2. Time delay to take action defaults to 10 seconds for Warning, Derate, and
Shutdown. The time delay to take action on low coolant level event can be
set within the range specified in the configuration table below.
Note: The Time Delay for Warning, Derate, and Shutdown are triggered
simultaneously. Notice in the table below, that as per Default Time Delays
the engine will simultaneously begin Warning and Derate 10 seconds after
the Coolant Level Switch changes state. If a customer desires a delay
between Warning, Derate, and Shutdown, then the Derate and Warning
Time Delay must be increased. For example, if Warning Time Delay is 10
seconds, Derate Time Delay is 20 seconds, and Shutdown Time Delay is
30 seconds. Then the warning will occur 10 seconds after the Coolant
Level Switch changes state. The Derate will occur 10 seconds after the
Warning begins. Finally, the Shutdown (if turned ON) will occur 10 seconds
after the Derate begins.
©2014 Caterpillar
The set point is determined by the coolant level sensor position, thus no
configuration is required. The following table summarizes the configuration default
settings and configuration ranges for low coolant level monitoring:
LOW COOLANT LEVEL MONITORING CONFIGURATION

Time Delay (sec) Set Points
Default
Action On/Off Range Default Range Default
Warning On 1-120s 10 N/A
Derate On 1-120s 10 N/A N/A
Shutdown Off 1-120s 10 N/A
7.1.3.1.3 Coolant Level Sensor Required Parts
Required Parts
Part Number Description Qty
331-7352 Coolant Level Sensor 1
364-7964 Wiring Kit 1
Note: Coolant Level Sensor 331-7352 has 1/4-18 NPTF threads.
7.1.3.2 Aux Temperature Sensor

7.1.3.2.1 Auxiliary Temperature Monitoring Operation
The auxiliary temperature measured by the ECU is compared to a maximum
auxiliary temperature limit configured in the monitoring system for auxiliary
temperature monitoring. The maximum auxiliary temperature is checked for each
ECU action level configured in the monitoring system. If the auxiliary temperature is
above the maximum auxiliary temperature for the specified action level delay time,
then the ECU takes the appropriate action to respond to the fault condition. Once
the fault is detected, the ECU illuminates the warning and diagnostic lamps and
logs the appropriate event code from the following table for the action taken:

Warning 441 15
High Auxiliary
Auxiliary Temperature #1 Derate 441 16
Temperature
Shutdown 441 00
The ECU can respond to the high auxiliary temperature condition with any or all
of the following actions: Warning, Derate, and Shutdown. The ECU logs an event
code and illuminates the lamps for all action levels. The ECU will respond with the
©2014 Caterpillar
following additional actions when the monitoring system is configured to Derate

and Shutdown:
 Derate: Engine power is reduced to 25 percent below rated power over 25
seconds (at a rate of one percent/second).
7.1.3.2.2 Auxiliary Temperature Monitoring Configuration

Three parameters can be configured in Cat ET to customize the monitoring
system for high auxiliary temperature monitoring.
1. ECU action for an event code defaults to “On” for Warning and “Off” for
Derate and Shutdown. All actions can be configured to “On” or “Off.”
2. Time delay to take action defaults to four seconds for Warning, Derate, and
Shutdown. Time delay to take action can be set between one and 120
seconds.
3. Auxiliary temperature maximum limit default for Warning is 193°C
(379°F), Derate is 196°C (385°F), and Shutdown is 200°C (392°F). The
maximum temperature limit for each action can be set within the range of
0°C and 250°C (0°C and 482°F).
The following table summarizes the configuration default settings and configuration
ranges for high auxiliary temperature monitoring:
HIGH AUXILIARY TEMPERATURE MONITORING CONFIGURATION

Default Time Delay (sec) Set Points
Action
On/Off Range Default Range Default
193°C
Warning On 1-120s 4
(379°F)
196°C
Derate Off 1-120s 4 0°C to 250°C
(385°F)
200°C
Shutdown Off 1-120s 4
(392°F)
Note: The engine must be running at engine speeds at or above low idle for 180
seconds before the above time delay is triggered.
7.1.3.2.3 Aux Temperature Sensor Required Parts
Required Parts
339-8822 Auxiliary Temperature Sensor 1
©2014 Caterpillar
Recommended mounting geometry can be seen in Figure 7.6 for this 339-8822
high-temp Auxiliary Temperature Sensor. This sensor has a stainless steel body and
is compatible with exhaust, coolant, and oil within the temperature limits described
above, but sensor body does not have provisions for an o-ring and sealing fluids
other than exhaust may prove to be problematic.
Figure 7.6
339-8822 Recommended Mounting Geometry (dims in mm)
Note: Ferrous port final installation tighten to 45 ± 5 N-m.
Note: Non-Ferrous port final installation tighten to 24 ± 3 N-m.
7.1.3.3 Auxiliary Pressure Sensor

7.1.3.3.1 Auxiliary Pressure Monitoring Operation
Auxiliary pressure is monitored to automatically protect a customer-defined
system from exceeding the maximum pressure limit of that system. The auxiliary
pressure measured by the ECU is compared to a maximum auxiliary pressure limit
configured in the monitoring system for auxiliary pressure monitoring. The
maximum auxiliary pressure is checked for each ECU action level configured in the
monitoring system. If the auxiliary pressure is above the maximum auxiliary
pressure for the specified action level delay time, then the ECU takes the
appropriate action to respond to the fault condition. Once the fault is detected, the
ECU illuminates the warning and diagnostic lamps and logs the appropriate event
code from the following table for the action taken:

Warning 1387 15
High Auxiliary Pressure Auxiliary Pressure #1 Derate 1387 16
Shutdown 1387 00
©2014 Caterpillar
The ECU can respond to the high auxiliary pressure condition with any or all of
the following actions: Warning, Derate, and Shutdown. The ECU logs an event
code and illuminates the lamps for all action levels. The ECU will respond with the
following additional actions when the monitoring system is configured to Derate
and Shutdown:
 Derate: Engine power is reduced to 25 percent below rated power over 25
seconds (at a rate of one percent/second).
7.1.3.3.2 Auxiliary Pressure Monitoring Configuration
Three parameters can be configured in Cat ET to customize the monitoring
system for high auxiliary pressure monitoring.
1. ECU action for an event code defaults to “On” for Warning and “Off” for
Derate and Shutdown. All actions can be configured to “On” or “Off.”
2. Time delay to take action defaults to four seconds for Warning and three
seconds for Derate and Shutdown. Time delay to take action can be set
between one and 120 seconds.
3. Auxiliary pressure maximum limit default for all events is 1500 kPa. The
maximum pressure limit for each action can be set within the range of 0
kPa and 3150 kPa.
The following table summarizes the configuration default settings and
configuration ranges for high auxiliary pressure monitoring:
HIGH AUXILIARY PRESSURE MONITORING CONFIGURATION

Default Time Delay (sec) Set Points
Action
On/Off Range Default Range Default
Warning On 1-120s 4
Derate Off 1-120s 3 0 kPa to 3150 kPa 1500 kPa
Shutdown Off 1-120s 3
Note: The engine must be running at engine speeds at or above low idle for 180
seconds before the above time delay is triggered.
7.1.3.3.3 Aux Pressure Sensor Required Parts
Required Parts
320-3064 Auxiliary Pressure Sensor 1
©2014 Caterpillar
Note: Auxiliary Pressure Sensor 320-3064 has 1/2-20 STOR threads. The sensor
has an operating temperature limit of 125°C (257°F) max and an accuracy
of about +/- 55 kPa
7.1.4 Alarms and Shutdowns
Cat C15 SCAC Hazardous Location engines are available with a factory-installed
ATEX compliant air shutoff valve. If either of the two engine speed sensors signals
an overspeed event to the ECM, the ECM disables the engine fuel injectors and
triggers the air shutoff valve.
A certified electronic solenoid valve controls the flow of engine oil to the air
shutoff valve. As long as the solenoid valve is receiving power from the ECM, it
allows engine oil pressure to hold the air shutoff valve in the OPEN position. If
power is cut to the ECM, if the ECM detects engine overspeed, or if a stop button
(switch to ground wired to the customer harness pin J1-46) is pressed, power will
be cut to the solenoid valve and fuel injectors. Loss of power to the solenoid valve
will stop engine oil flow to the air shutoff valve and cause the valve to close.
Pulling the lever shown in Figure 7.7 will also manually close the air shutoff valve.
Refer to Appendix A3 for C15 air shutoff ECM pin locations.
Note: The air shutoff will need to be enabled in CatET. Please refer to the
information in Electronics A&I Guide, LEBH4623, for information on the
default software settings for this feature and how to enable this in CatET.
In order to start the engine and/or reset the air shutoff valve after it has been
actuated, the air shutoff valve lever must be held open until the engine is started
and engine oil pressure is sufficient to hold the air shutoff valve in the OPEN
position. Two methods can be used to hold the air shutoff valve OPEN when
starting the engine. First, the operator can open the air shutoff valve with the lever
and engage the STARTUP LATCH shown in Figure 7.7. Second, a customer-
installed mechanism can be connected to the air shutoff lever to hold it OPEN when
starting the engine. This mechanism could be cable actuated, air actuated, etc.
Always heed the following warning that is attached to the air shutoff valve
shown in Figure 7.7:
Do not restrict reset latch or tie-off reset lever. This safety device
senses specific unsafe engine operating conditions (high
temperature, low oil pressure, overspeed if equipped). Shutdown
will occur to prevent severe engine damage.
©2014 Caterpillar
Figure 7.7
C15 Air shutoff valve with manual actuation lever, startup latch and solenoid
valve
The C15 Hazardous Location engine is equipped with sensors to monitor oil
pressure and coolant temperature. Display units that are appropriately connected to
the ECM via the Customer Harness can display alarms that are triggered by these
sensors. Additionally, the auxiliary temperature sensor discussed in section 7.1.3
can trigger an alarm for high exhaust gas temperature.
Although the ATEX Standards only require an automatic alarm for oil pressure,
coolant temperature, and exhaust gas temperature, the C15 Hazardous Location
ECM can be configured to automatically derate and/or shutdown the engine for any
of these conditions.
Testing of the Air shutoff system can be actuated via an Overspeed Verify switch
on ECM connector J1 pin 54. For more details on operation of the Overspeed
Verify switch, please refer to the Electronics A&I Guide, LEBH4623.
©2014 Caterpillar
Testing of the auxiliary pressure and temperature sensor shutdown functionality

can be actuated by manually configuring the shutdown limits to below normal
operating pressures/temperatures.
The C7, C9, and C32 hazardous location engines provide an ECM output to
control customer-provided air shutoffs or air shutoff actuators. Appendix A2 lists
ECM inputs and outputs for these engines. ECM Pin 11 on the C7, C9, and C32
engines provides a +V output of up to 2A when overspeed is detected or when
the overspeed verify switch is enabled. During normal operation the pin voltage is
floating and provides neither positive voltage nor ground. This behavior makes Pin
11 unsuitable for controlling an air shutoff on engines for which EN 1834-1
compliance is desired. For engines which must meet the requirements of EN 1834-
1, a separate overspeed shutdown controller will need to be installed.
The C15 hazardous location engine provides a switched input to the ECM to
trigger a shutdown. When pin 46 is connected to ground the ECM will allow the
air shutoff valve to close and will stop fueling the engine.
Figure 7.8
Remote shutdown is available on pin 44 of the C7, C9, and C32 engines but
controls fuelling only. Air shutoff actuation can be driven separately by the
customer.
The C7-C32 ACERT industrial engines all have programmable alarms, derates, and
shutdowns for coolant temperature. See media number LEBH4623 for details of
these settings. The C15 hazardous location engine offers an expanded range of
temperatures for alarm/derate/shutdown programmed setpoints. For the C15 the
range is 38°C to 111°C [100°F to 232°F], whereas the other C11 to C32 engines
offer a range of 87°C to 111°C [189°F to 232°F].
7.2 Cooling System

7.2.1 System Pressure
Cat hazardous location engine cooling systems require a system pressure of 138
kPa [20 psi]. This requires the customer to use a 138 kPa [20 psi] radiator and/or
expansion tank cap.
7.2.2 Mandatory Venting
For C7 and C9 Hazardous Location engines, a vent line must be installed by the
customer that leads from the port at the top of the turbocharger with a gradual
upward slope to a higher point in the system. Consideration should be taken so
that there are no high points in the line to potentially trap air. An additional port is
©2014 Caterpillar
provided in the “T” fitting at the top of the turbocharger for this vent line
installation.
Note: It is important that this line vents to a pressurized location (138 kPa [20
psi] cap) in order to sustain localized pressure at the top port of the
turbocharger. It is recommended to vent to the radiator top tank.
Note: A 6.5 mm [0.25 in] inner diameter vent line should be used.
Note: Additional venting does not need to be installed on the turbocharger of the
C15 or C32 Hazardous Location engines.
7.3 Ambient Temperature Sensor (Derating C7 and C9)

For a derated hazardous location engine, an additional ambient temperature
sensor must be installed for the software to function properly. This sensor is a
ship-loose item with every derated engine.
The sensor must be installed in the intake system between the air cleaner and
turbocharger compressor inlet (Figure 7.9). The bushing used should have a
minimum thread engagement of 10 mm [0.39 in] with a maximum boss height of
no more than 15 mm [0.59 in]. This is to ensure the sensor is fully immersed into
the intake air flow.
Note: A STOR port size of 3/8-24 is required for the ambient temperature sensor
provided by Cat (sensor part number 329-1464).
Figure 7.9
Ambient Temperature Sensor Recommendation
©2014 Caterpillar
7.4 Flame Proof Engine

7.4.1 C7, C9, C32 Hazardous Location Engines
Improper installation of this engine into a package may result in

personal injury or death due to the hazardous environment in which
it is installed. It is ultimately the responsibility of the packager to
ensure that the complete intake system, exhaust system and all
peripherals meet EN 1834-1 and any other applicable standards for
an ATEX compliant installation. Failure to heed this warning can
lead to premature failures, product damage, personal injury or
death.”
Such peripherals include but are not limited to:

 Flameproof Intake System - The packager is responsible for installing a
certified intake flame arrestor. The packager must ensure that any intake
system components downstream of the flame arrestor are compliant with
EN 1834-1. These components could include the turbocharger, charge air
piping, and charge air cooler.
 Flameproof Exhaust System - The packager must ensure that any exhaust
system components are compliant with EN 1834-1. These components
could include the exhaust manifold and turbocharger.
 Breather System - The breather system on Cat Petroleum Hazardous
Location Engines is an open system (crankcase to atmosphere). Flame
proofing (flame arrestor) is not required. The breather system maintains
positive pressure in the crankcase during normal operation. Additionally,
during normal operation, there are no effective ignition sources inside the
crankcase.
 Oil Level Gauges - The oil gauges also need to be flame proof (C32).
 Oil Fillers – All oil fillers also need to be flame proof.
 Air Shut-offs - Air shut-offs function to protect the engine from “running
away” - a condition where combustible gasses are ingested by the engine
and can cause an overspeed event even when fuel to the cylinders has
been shut off.
 Flame Arrestors - Use of flame arrestors in the intake and exhaust systems
prevents a possible ignition source initiating from the engine.
 Spark Arrestors - Spark arresting mufflers are used to prevent an ignition
source condition from forming at the exhaust outlet of the engine.
©2014 Caterpillar
 Separate Circuit Aftercooler Condensation Drain (C7, C9, and C32 only) –
The SCAC condensation drain that comes standard on SCAC hazardous
location engines, is not certified to be flameproof. A flame arrestor should
be applied at this location.
Consultation with a third party packager that specializes in hazardous location
installations is recommended when addressing the above recommendations.
7.4.2 C15 Hazardous Location Engine
The C15 Hazardous Location SCAC engine is equipped with a flameproof intake
system that has been type tested and approved to EN 1834-1 for Gas Group IIA
and Temperature Class T3 with an ambient capability of 50°C. This intake system
is highlighted in Figure 7.10 below.
Figure 7.10
©2014 Caterpillar
NEVER reuse any clamps, seals, or gaskets in the flameproof intake

or exhaust system. Always replace clamps, seals, and gaskets with
new, exact part number parts when servicing. Failure to heed this
injury, or death.
The system includes an intake flame arrestor that is mounted to the inlet of the
turbocharger on a cast intake elbow, the turbocharger compressor, charge air pipe,
butterfly style air shutoff valve, high pressure hump hose, the on-engine charge air
cooler, and a flame arrestor in the charge air cooler condensation drain port.
The flameproof intake system is designed with tight seals, closely matched joints,
and robust enclosures to prevent any internal flames or explosions from
propagating to the exterior atmosphere.
A unique intake connection to the C15 Hazardous Location SCAC engine will be
required because of the 12-inch diameter flame arrestor that is incorporated into
the turbocharger inlet. A 12-inch hump hose is available to allow an air cleaner and
ductwork to be attached to the intake flame arrestor.
The published air intake system limit includes the entire intake system,
atmosphere to turbocharger inlet. The flame arrestor provided on the C15
Hazardous Location engines consumes 0.6 kPa of the allowable limit published in
TMI.
The flameproof intake system requires additional maintenance beyond the
standard engine maintenance schedule. The engine-specific Operation and
Maintenance Manual should be consulted.
Note: When removing the SCAC condensation drain flame arrestor for cleaning,
always replace the o-ring seal with a new seal. Use the appropriate mandrel
to install the new seal in order to prevent seal damage.
7.5 Exhaust Gas Cooler

Exhaust gas coolers are another mandatory installation requirement per EN1834 if
the exhaust gas is released into a hazardous area.
It is allowable to divert coolant from the jacket water circuit for an exhaust gas
cooler. Care must be taken that the cooling system is sized adequately to prevent
engine overheating at the installation site’s maximum ambient temperature.
Consideration must also be made for the additional restriction caused by diverting
coolant for a gas cooler. The entire jacket water cooling system restriction, external
©2014 Caterpillar
to the engine, must lie within the limits of the published jacket water pump flow
curve in order to maintain an adequate flow rate.
For engines that utilize separate circuit aftercoolers (SCAC), coolant from this
circuit can also be diverted for an exhaust gas cooler as long as the aftercooler
coolant inlet design temp is maintained. The external restriction of this circuit must
also lie within the limits of the published SCAC pump curve so as to maintain
adequate flow.
On C15 Petroleum engines, an optional jacket water diverter bonnet is available
to provide a cooling circuit for auxiliary cooling (ex: exhaust gas coolers). This
feature and reference circuit points are shown in Figure 7.11 below. The auxiliary
cooler flow versus restriction data can be found in TMI Performance Data DM9276
and is used to determine water flow through this circuit (Aux Cooler Out to Aux
Cooler Return). System integrators can use the equation in DM9276 to calculate
the overall system flow reduction from the restriction added by this circuit. This
equation is provided because the bonnet is not a 100% flow diversion. An example
calculation is provided below.
Note: The data in DM9276 assumes a 35 kPa @ 2000 RPM radiator restriction
from the EM0257 (TMI performance data) JW circuit (thermostat outlet to
JW pump inlet).
Note: Caterpillar recommends using the standard engine oil cooler bonnet for
applications that do not require an auxiliary cooler in the JW circuit.
Thermostat Outlet
Water Pump Inlet

Aux Cooler Return Aux
Cooler Out Figure 7.11
©2014 Caterpillar
Example Calculation
(1) The two parameters which need to determined for this calculation are the
restrictions of the Radiator circuit and Aux cooler circuit. For the purposes of
this example, assume:
 At rated conditions, Radiator circuit (JW thermostat out to JW pump in)
restriction = 31kPa
 At rated conditions, Aux cooler circuit restriction (Aux Out to Aux In) =
15kPa
(2) From TMI JW pump curve EM0257 determine the baseline Radiator flow:
Engine Speed RPM: 2000
Pump Speed RPM: 2162
EXT RESIST M EXT FLOW
H20 L/MIN
3.1 489
3.6 483
4.1 477
4.6 471
(3) Since the Aux cooler flow data in DM9276 assumes 35kPa restriction of the
Radiator circuit, first calculate the JW flow at that restriction. Linear
interpolation of 35kPa (3.57 m H2O) in the above EM0257 data table yields
483.4 L/min.
(4) Now, determine the flow rate of the given system using interpolation of
EM0257. For this example system, 31kPa (3.1 m H2O) corresponds to 489
L/min of Radiator circuit flow.
(5) Correcting the 35kPa assumption in DM9276 to the desired restriction of
31kPa (3.1 m H2O) of this example system yields an offset of 489 - 483.4 =
5.6 L/min.
(6) From TMI Aux circuit data DM9276 the Aux circuit flow can now be
calculated:
(7) Linear interpolation using the assumed Aux circuit restriction of 15kPa (1.53
m H2O) in the above DM9276 data table yields 331.6 L/min.
(8) To adjust this value for the 31 kPa Radiator circuit restriction (instead of
35kPa), use the result from line (5) with the result from line (7) to find 331.6
+ 5.6 = 337.2 L/min.
©2014 Caterpillar
(9) Finally, adjustment to the Radiator circuit flow should be made based upon
the flow that has been calculated for the Aux circuit. The equation for this is
shown in DM9276 as:
Flow Change (L/min) = -10.408 * (Aux. Cooler Restriction in m H2O) - 9.8581
(10) Inputting 15kPa (1.53 m H2O) into this equation yields a Flow Change of -
25.8 L/min.
(11) The resulting Radiator circuit flow of this system using the results from lines
(4) and (10) is calculated to be 489 - 25.8 = 463.2 L/min.
Results:
 At rated conditions, Aux circuit flow is 337.2 L/min.
 At rated conditions, Radiator circuit flow is 463.2 L/min.
Example C7 / C9 SCAC Cooling System with Exhaust Cooler

C7 SCAC ATEX Cooling System (ref feature C07DW11)
Cooler / Radiator Cooler / Radiator
Bypass T-stat
Pump Tee
Regulator
Pump
Aftercooler
Engine
Cat-supplied lines
Customer-supplied lines
Note: Thermostat and bypass are shown relocated off-engine

by the customer to facilitate connection of an exhaust gas Exhaust
cooler on the engine coolant circuit Cooler
Figure 7.12
©2014 Caterpillar
Example C15 SCAC Cooling System with Exhaust Cooler
Caterpillar-supplied lines
Figure 7.13
Example C32 SCAC Cooling System with Exhaust Cooler
Caterpillar-supplied lines
Figure 7.14
©2014 Caterpillar
7.6 Altitude
It is the responsibility of the package OEM to maintain temperature compliance in
all operating conditions and elevations for a given application. Caterpillar T3
temperature compliance is limited by the charge air intake system and is verified at
500ft ASL elevation under standard lab conditions. Prior to operating at altitudes
above this test condition in locations where T3 limits must be met, equipment
compliance with the T3 limit must be confirmed. If it is found that the T3 limit is
exceeded, contact customer service immediately.
8 ATEX Certified Attachments

8.1 Customer Supplied Attachments
In addition to the components offered by Caterpillar on hazardous location
engines, additional attachments may be required by customers in order to meet the
needs of their application. These attachments could include:
 Alternators
 Coolant level sensors
 Starters
 Air compressors
 Anti-static fans
 Air Shutoffs
 Solenoids
 Turbocharger Exhaust Outlet Adapters
 Mufflers and other exhaust system components
 Throttle positioning sensors/controls
 Monitoring Displays
The customer must ensure that any attachments added to a Cat Hazardous
Location Engine are certified to meet the applicable hazardous location standards.
8.2 Caterpillar Supplied Optional Attachments

Caterpillar offers a limited selection of ATEX certified optional attachments for
the Hazardous Location engine platforms. These may include:
 Alternators
 Air compressor
 Throttle control
 Messenger Display
©2014 Caterpillar
 Coolant Level Sensor – refer to section 7.1.3

 Auxiliary Temperature Sensor (Exhaust Gas temperature monitoring) – refer
to section 7.1.3
 Auxiliary Pressure Sensor – refer to section 7.1.3
 Anti-static belts (see PowerNet for a list of currently available belts that are
certified to ISO 1813 for electrical conductivity of anti-static belts)
 Air Shutoff & solenoid (C15 only) – refer to section 7.1.4
Hazardous Location certificates for all Caterpillar supplied certified components
such as these are available via PowerNet.
8.2.1 Alternators
Two Hazardous Location certified alternators are available from Caterpillar.
298-8838 Class 1 Division 2 non-sparking alternator is CSA certified for use in
the US and Canada. It is certified for NEC Gas Groups C&D and Temperature Class
T3B with an ambient temperature of -40°C < Ta < +93°C. It must be used with
the 298-8840 Class 1 Division 2 CSA certified harness for battery +/-
connections. When this alternator is purchased for use with the C15 Petroleum
Hazardous Location engine, it can be installed or shipped loose from the factory.
The alternator is shipped with a pulley that will limit alternator speed with a pulley
ratio of 3.500. This speed limiting is a requirement to maintain the Class 1 Division
2 certification. This alternator is an extra heavy duty brushless 26 SI unit. Output
capability is 24V 65A (for complete performance, please see Appendix A5).
371-5017 alternator is ATEX certified for use in Category 2G (Zone 1) hazardous
locations. It is certified for ATEX Gas Group IIB and Temperature Class T3 with an
ambient temperature of -40°C < Ta < +93°C. This alternator is a 24V 35A
flameproof unit (output performance shown in Appendix A6). When this alternator
is purchased for use with a C9 or C15 Petroleum Hazardous Location engine, it can
be installed or shipped loose from the factory. With the C32 engine, the alternator
is available as shipped-loose only, but mounting brackets are included. The
alternator is shipped with a pulley that will limit alternator speed to below 8500
RPM and comes with a 25 foot un-terminated cable to pass through battery box
connections via an ATEX certified cable gland. This gland needs to be selected per
the cable size chart shown in Figure 8.1.
The ATEX alternator has been upgraded, and version 3 (371-5017 -03-)
incorporates the load dump diode and energizing resistor internally. These
alternators can be identified by the Cat part number label or by the manufacturer’s
serial number which will be #10064 or higher for version 3.
For version 2 and earlier (371-5017-02-), the following recommendations apply:
As part of the termination of this cable in the battery box, a Zener diode is
recommended to protect against load dump events such as opening the master
disconnect switch. This diode should be incorporated across the B+ and B- battery
connections in the alternator circuit. A diode with a max Irms of 85A and nominal
©2014 Caterpillar
zener voltage of 39V to 47V should be selected for this function. A wire
designation for the selected cable is shown in Figure 8.2. The phase is the AC tap
from the stator (frequency (Hz) = Alternator Speed RPM /10). The alternator is
energized through the Charge Warning Light (CWL). The CWL is connected
between the B+ and the D+ through the run position of the key switch. It is
allowable to use a 100 ohm 10 W resistor in place of the CWL. The CWL will only
light at 0 RMP or other non-charging condition.
Wire Designations:
Brown D+ (Lamp)
White B+ (Battery Positive)
Black B- (Battery Negative)
Blue P (Phase) Figure 8.1
Grounding Points
B (Battery -)
B (Battery +) (White)
D+ (Ignition Input)
P (Phase)
Metal Inner Sheath

Grounding between
glands connections
Control Box Wiring for V02 and Earlier

Figure 8.2
©2014 Caterpillar
It is the customer’s responsibility to properly terminate the end of

the supplied alternator cable. Steps must be taken to ensure the
wiring installation meets the site’s local hazardous location
directives and is appropriate for the application. Failure to heed this
injury, or death.
The alternator contains no user serviceable parts. DO NOT

DISMANTLE. Any failed units should be replaced with a new,
exact part number. Failure to heed this warning can lead to
premature failures, product damage, personal injury, or death
8.2.2 Air Compressor

There is a 351-7086 Air Compressor available from Caterpillar that is ATEX
certified for use in Category 3G (Zone 2) environments when installed on the C15
Petroleum Hazardous Location engine. This compressor is a single cylinder, gear
driven unit that is engine oil lubricated and water cooled. The compressor is
certified to Gas Group IIA and Temperature Class T3 with an ambient temperature -
30°C < Ta < +50°C.
Note: A governor with a maximum 140 psi cut-out pressure must be used to
maintain this air compressor’s certification. There are two governor options
available from Caterpillar:
 4N-9680 (120 psi)
 7N-9195 (135 psi)
Note: It is the customer’s responsibility to properly connect the inlet and
discharge of the compressor to equipment that meets the hazardous
location requirements of the site. Inlet air should be filtered and provided at
ambient pressure (naturally aspirated) with a maximum temperature of
50°C [122°F].
©2014 Caterpillar
Figure 8.3
8.2.3 Throttle Control

There is an available 365-2189 Throttle Control which is ATEX certified for use in
Category 3G (Zone 2) environments and NEC certified for use in Class 1 Division
2/Zone 2 environments. This throttle control is certified for ATEX Gas Group IIC
and NEC Gas Groups ABCD. This throttle control is certified for Temperature Class
T3 with an ambient temperature capability of -40°C < Ta < +85°C.
The throttle control needs to be mounted in a box or on a plate that protects the
unit from potential impact. The power wiring may be wired as intrinsically safe
provided that the current from the battery is limited by a carbon film, metal film, or
wire wound resistor at the point where the power leaves the battery enclosure.
Capacitance (Ci) for the power wiring is 0.22 μF, and inductance (Li) is 0.6 mH.
The signal wire may be treated as intrinsically safe if the completed circuit meets
the requirements of IEC 60079-11. For the signal wire, Ci is 0.73 nF and Li is 1.2
mH.
©2014 Caterpillar
Figure 8.4
Minimum Required Maximum Required

Battery Resistor Value Minimum Resistor Value Minimum
Comments
Voltage for ic Protection Resistor Power for Device Resistor Power
Concept, Rmin Rating @ Rmin Function, Rmax Rating @ Rmax
* Will not
function
24 V when battery
170 Ohm 7.3 W 479 Ohm* 2.6 W
(28.8 V) voltage is
below 21V
w/Rmax
Note: The voltages shown in parentheses are those that could occur in alternator
charged lead-acid battery systems.
Table 8.1
If an intermediate resistance value is used, the minimum power rating of the
resistor must be (I2R) X 1.5, where:
Maximum Batt System Voltage
I=
Resistor Value
Refer to LEBH4623 for the PWM throttle configuration procedure and additional
information about the available speed input options.
8.2.4 Messenger Display
The 371-7686 Messenger Display is ATEX certified for use in Category 3G (Zone
2) environments and NEC certified for use in Class 1 Division 2/Zone 2 hazardous
locations. The Messenger Display is certified for ATEX Gas Group IIC and NEC Gas
Groups ABCD. The Messenger Display is certified for Temperature Class T3 with an
ambient capability of -10°C < Ta < +80°C.
The internal features of the messenger display, such as signal circuits and
pushbuttons, are isolated from the supplied power by internal power regulation and
distribution circuitry, and the ic (intrinsically safe) protection concept applies to the
internal circuitry.
©2014 Caterpillar
Pins 4, 5 and 6 are not currently used when the messenger display is connected
to a hazardous location engine. Pins 1, 2, 3, 7, and 8 must be connected for the
display to operate.
The external wiring for the power
supply is not intrinsically safe / non-
incendive, and should be wired using
field wiring methods suitable for the
relevant area classification(s). To meet
the essential health and safety
requirements of the ATEX directive, the
completed installation needs to meet
the requirements of 60079 Part 0 as Figure 8.5
well as other applicable standards. The
messenger display must be mounted in an enclosure that meets the material and
impact requirements of EN 60079-0.
The installer will likely need to reference 60079 Part 15: Equipment protection by
type of protection "n" and 60079 Part 14: Electrical installations design, selection
and erection to fully protect against sources of ignition. For Class 1 Division 2
locations, refer to NEC 501.10 and other relevant standards. See API RP 14F and
14FZ for additional wiring recommendations. The data wiring may be treated as
intrinsically safe if the combined circuit with all connected devices meets the
requirements of IEC 60079-11. At the signal connections of the messenger display,
Ci is 220 pF, and Li is 0.7 μH.
Additional information about CAN bus wiring for the messenger display can be
found in LEBH4623 Electronics A&I for Industrial C7-C32 ACERT
Figure 8.6
Note: The messenger display certificate names part number 365-7647. Display
group 371-7686 is the serviceable level of this part, and includes both the
physical hardware and the installed software flash file. Part number 365-
7647 as shown on the certificate refers to the physical hardware within
that group, without the software flash file, and the part is not serviceable
at that level.
©2014 Caterpillar
9 Engine Documentation
9.1 EU Declaration of Incorporation
The Declaration of Incorporation (DOI) is available via PowerNet for every Cat
Petroleum Hazardous Location Engine. This document is required for engines
shipped to or within the EU for free movement of goods, or as requested by a
customer order, per the applicable Machinery Safety Directive, 98/37/EC or
2006/42/EC after December 29, 2009.
Note: Machinery Safety compliance is self-assessed by Caterpillar.
9.2 EU Declaration of Conformity

The Declaration of Conformity (DOC) is another document that is available via
PowerNet for every Cat Petroleum Hazardous Location Engine. This document
states compliance to the EU Explosive Atmosphere (ATEX) Directive 94/9/EC and
Electro Magnetic Compatibility Directive (EMC) 2004/108/EC of engine installations
into larger, more complex pieces of machinery.
Note: EMC is self-assessed by Caterpillar.
The ATEX certification for Cat Petroleum Hazardous Location Engines is 3rd party
evaluated and certified. 3rd party certificates are available for each engine. See
Table 9.1 for the applicable 3rd party certification depending on the region in which
the engine will operate.
Certification Bodies by Type and Region

Class I Division 2 / Zone 2
ATEX
(North America)
Electrical Electrical Mechanical
C7, C9, Pyroban /
Factory Mutual (FM) SIRA
and C32 Intertek
C15 Intertek Det Norske Veritas (DNV)
Table 9.1
©2014 Caterpillar
A 1 - C7, C9, C32 Hazardous Location Connector (J1/P1)

Pinout and Load Table
Pin Wire Signal Assignment Voltage Current Pin Wire Signal Assignment Voltage Current
1 Unused 36 Unused
Analog Sensor
2 18 AWG Supply 5 VDC 40 mA 37 Unused
Power (+5V)
Common Analog Sensor
3 18 AWG 38 Unused
Ground Return
Digital Sensor
4 18 AWG Supply 8 VDC 40mA 39 Unused
Power (+8V)
Retarder Solenoid
Common Digital Sensor 18 Switch to Medium/High or
5 18 AWG 40 13 VDC 6.5 mA
Ground Return AWG Ground Exhaust Brake
Enable
Switch to Maintenance Clear 18 Switch to PTO Interrupt
6 18 AWG 13 VDC 6.5 mA 41 13 VDC 6.5 mA
Ground Switch AWG Ground Switch
Switch to 18 Per
7 18 AWG Torque Limit Switch 13 VDC 6.5 mA 42 Data Link J1939 Shield
Ground AWG J1939
8 18 AWG Data Link + Cat Data Link (+) 5 VDC 100 mA 43 Unused
18 Switch to Remote Shutdown
9 18 AWG Data Link - Cat Data Link (-) 5 VDC 100 mA 44 13 VDC 6.5 mA
AWG Ground Switch
Intermediate Speed
Ether Start Valve 18 Switch to
10 16 AWG High Side Battery 2 Amp 45 Switch or Idle/Rated 13 VDC 6.5 mA
Solenoid/Relay AWG Ground
Switch
11 16 AWG High Side Air Shutoff Relay Battery 2 Amp 46 Unused
12 Unused 47 Unused
Exhaust Brake 14 + Battery Un-
13 16 AWG High Side Battery 2 Amp 48 Supply Battery 10 Amp
Driver AWG switched
18 Switch to Coolant Level
14 Unused 49 5 VDC 10 mA
AWG Ground Switch
Auxiliary Pressure 18 Per
15 18 AWG Analog Input 5 VDC 20 mA 50 Data Link J1939 (+)
Sensor AWG J1939
Auxiliary
Passive
16 16 AWG Temperature 5 VDC 10 mA 51 Unused
Analog Input
Sensor
14 + Battery Un-
17 Unused 52 Supply Battery 10 Amp
AWG switched
14 + Battery Un-
AWG switched
18 Switch to Overspeed Verify
19 18 AWG High Side Wait to Start Lamp Battery 2 Amp 54 13 VDC 0.6 mA
AWG Ground Switch
14 + Battery Un-
AWG switched
18 Switch to
21 Unused 56 PTO Enable Switch 13 VDC 6.5 mA
AWG Ground
22 Unused 57 DO NOT USE
Switch to Retarder Solenoid 18 Switch to PTO Ramp Up/Set
23 18 AWG 13 VDC 6.5 mA 58 13 VDC 6.5 mA
Ground Low/High AWG Ground Switch
24 18 AWG DF PWM (+) Timing Cal (+) 0 10 mA 59 Unused
18 Switch to PTO Ramp
25 18 AWG DF PWM (-) Timing Cal (-) 0 10 mA 60 13 VDC 6.5 mA
AWG Ground Down/Resume
14
26 Unused 61 Ground - Battery
AWG
27 Unused 62 Unused
14
28 18 AWG Low Side Diagnostic Lamp Battery 0.3 Amp 63 Ground - Battery - Battery 10 Amp
AWG
29 18 AWG Low Side Warning Lamp Battery 0.3 Amp 64 Unused
Maintenance Due 14
30 18 AWG Low Side Battery 0.3 Amp 65 Ground - Battery - Battery 10 Amp
Lamp AWG
18 Throttle Position
31 18 AWG Low Side Retarder Lamp Battery 0.3 Amp 66 PWM Input 5 VDC 40 mA
AWG Sensor
14 Common ASO Solenoid
32 Unused 67 - Battery 10 Amp
AWG Ground Common
33 Unused 68 Unused
Per 14
34 18 AWG Data Link J1939 (-) 69 Ground - Battery - Battery 10 Amp
J1939 AWG
18 Switch to +
35 Unused 70 Key Switch Input Battery 1.2 mA
AWG Battery
©2014 Caterpillar
A 2 – C7 Hazardous Location Customer Harness Wire Table

ECU (J1/P1)
Description
Pin
Ether Start Valve Solenoid/Relay 10
Air Shutoff Relay 11
Diagnostic lamp 28
Warning Lamp 29
Maintenance Due Lamp 30
Retarder Lamp 31
Incendive Loom
+ Battery Un-Switched 48
- Battery 61
- Battery 63
- Battery 65
ASO Solenoid Common 67
- Battery 69
+ Battery Key Switch Input 70
Analog Sensor Power (+5V) 2
Analog Sensor Return 3
Digital Sensor Power (+8V) 4
Digital Sensor Return 5
Maintenance Clear Switch 6
Torque Limit Switch 7
Cat Data Link (+) 8
Cat Data Link (-) 9
Auxiliary Pressure Sensor 15
Non-incendive Loom
Auxiliary Temperature Sensor 16
Unused 22
Retarder Solenoid Low/High 23
J1939 (-) 34
Retarder Solenoid Medium/High or Exhaust Brake Enable 40
PTO Interrupt Switch 41
Remote Shutdown Switch 44
Intermediate Speed Switch 45
Coolant Level Switch 49
J1939 (+) 50
Overspeed Verify Switch 54
PTO Enable Switch 56
PTO Ramp Up/Set Switch 58
PTO Ramp Down/Resume 60
Throttle Position Sensor 66
Unused 68
(1) Customer Harness has non-terminated “pigtail” ends. Wires are labeled per the
corresponding J1/P1 ECU pin.
©2014 Caterpillar
A 3 – C15 Hazardous Location ECU Connector (J1/P1)

Pinout & Load Table
Pin Wire Signal Assignment Voltage Current Pin Wire Signal Assignment Voltage Current
1 Unused 36 Unused
Analog Sensor Power
2 18 AWG Supply 5 VDC 40 mA 37 Unused
(+5V)
Common
3 18 AWG Analog Sensor Return 38 Unused
Ground
Digital Sensor Power
4 18 AWG Supply 8 VDC 40mA 39 Unused
(+8V)
Retarder Solenoid
Common 18 Switch to
5 18 AWG Digital Sensor Return 40 Medium/High or 13 VDC 6.5 mA
Ground AWG Ground
Exhaust Brake Enable
Switch to Maintenance Clear 18 Switch to
6 18 AWG 13 VDC 6.5 mA 41 PTO Interrupt Switch 13 VDC 6.5 mA
Ground Switch AWG Ground
Switch to 18 Per
7 18 AWG Torque Limit Switch 13 VDC 6.5 mA 42 Data Link J1939 Shield
Ground AWG J1939
8 18 AWG Data Link + Cat Data Link (+) 5 VDC 100 mA 43 Unused
18 Switch to Remote Shutdown
9 18 AWG Data Link - Cat Data Link (-) 5VDC 100 mA 44 13 VDC 6.5 mA
AWG Ground Switch
Ether Start Valve 18 Switch to Intermediate Speed
10 16 AWG High Side Battery 2 Amp 45 13 VDC 6.5 mA
Solenoid/Relay AWG Ground Switch
18 Switch to Air & Fuel Shutoff
11 Unused 46 13 VDC 6.5 mA
AWG Ground Switch
12 16 AWG High Side Starter Motor Control Battery 2 Amp 47 Unused
14
13 16 AWG High Side Exhaust Brake Driver Battery 2 Amp 48 Supply + Battery Un-switched Battery 10 Amp
AWG
18 Switch to
14 Unused 49 Coolant Level Switch 5 VDC 10 mA
AWG Ground
Analog Auxiliary Pressure 18 Per
15 18 AWG 5 VDC 20 mA 50 Data Link J1939 (+)
Input Sensor AWG J1939
Passive
Auxiliary Temperature
16 16 AWG Analog 5 VDC 10 mA 51 Unused
Sensor
Input
14
17 Unused 52 Supply + Battery Un-switched Battery 10 Amp
AWG
Common 14
18 18 AWG Digital Sensor Return 53 Supply + Battery Un-switched Battery 10 Amp
Ground AWG
18 Switch to Overspeed Verify
19 18 AWG High Side Wait to Start Lamp Battery 2 Amp 54 13 VDC 0.6 mA
AWG Ground Switch
14
20 Unused 55 Supply + Battery Un-switched Battery 10 Amp
AWG
18 Switch to
21 Unused 56 PTO Enable Switch 13 VDC 6.5 mA
AWG Ground
Switch to CX Transmission
22 18 AWG 13 VDC 6.5 mA 57 DO NOT USE
Ground Governor Mode Switch
Switch to Retarder Solenoid 18 Switch to PTO Ramp Up/Set
23 18 AWG 13 VDC 6.5 mA 58 13 VDC 6.5 mA
Ground Low/High AWG Ground Switch
DF PWM
24 18 AWG Timing Cal (+) 0 10 mA 59 Unused
(+)
18 Switch to PTO Ramp
25 18 AWG DF PWM (-) Timing Cal (-) 0 10 mA 60 13 VDC 6.5 mA
AWG Ground Down/Resume
14
26 Unused 61 Ground - Battery
AWG
27 Unused 62 Unused
14
28 18 AWG Low Side Diagnostic Lamp Battery 0.3 Amp 63 Ground - Battery - Battery 10 Amp
AWG
29 18 AWG Low Side Warning Lamp Battery 0.3 Amp 64 Unused
14
30 18 AWG Low Side Maintenance Due Lamp Battery 0.3 Amp 65 Ground - Battery - Battery 10 Amp
AWG
18 Throttle Position
31 18 AWG Low Side Retarder Lamp Battery 0.3 Amp 66 PWM Input 5 VDC 40 mA
AWG Sensor
14 Common ASO Solenoid
32 Unused 67 - Battery 10 Amp
AWG Ground Common
33 Unused 68 Unused
Per 14
34 18 AWG Data Link J1939 (-) 69 Ground - Battery - Battery 10 Amp
J1939 AWG
18 Switch to +
35 Unused 70 Key Switch Input Battery 1.2 mA
AWG Battery
©2014 Caterpillar
A 4 – C9, C15, C32 Hazardous Location Customer Harness Wire Table

Wire Marking ECU (J1/P1)
Description
Pin
Ether Start Valve Solenoid/Relay 382-ER37 10
Unused G971-ER19 11
Diagnostic Lamp F404-ER39 28
Warning Lamp F420-ER40 29
Maintenance Due Lamp F424-ER28 30
Retarder Lamp T936-ER18 31
Incendive Loom
+ Battery Un-switched 150-ER16 48
- Battery 229-ER59 61
ASO Solenoid Common G969-ER20 67
+ Battery Key Switch Input 120-ER6 70
Analog Sensor Power (+5V) I25-ER29 2
Analog Sensor Return T993-ER30 3
Digital Sensor Power (+8V) I67-ER23 4
Digital Sensor Return A274-ER24 5
Maintenance Clear Switch F426-ER27 6
Torque Limit Switch M909-ER17 7
Cat Data Link (+) 893-ER3 8
Cat Data Link (-) 893-ER4 9
CX Transmission Governor Mode Switch A742-ER9 22
Non-incendive Loom
Retarder Solenoid Low/High E716-ER49 23
Timing Cal + R723-ER69 24
Timing Cal - R724-ER70 25
J1939 (-) K990-ER5 34
Retarder Solenoid Medium/High or Exhaust Brake Enable E717-ER50 40
PTO Interrupt Switch M909-ER34 41
Remote Shutdown Switch F716-ER42 44
Intermediate Speed Switch (variable speed), Idle/Rated Switch (constant speed) G968-ER43 45
Air Shutoff Switch H401-ER68 46
J1939 (+) K900-ER2 50
Overspeed Verify Switch 387-ER55 54
PTO Enable Switch 381-ER44 56
PTO Ramp Up/Set Switch G955-ER45 58
PTO Ramp Down/Resume G967-ER54 60
Throttle Position Sensor A307-ER25 66
(1) Customer Harness has non-terminated “pigtail” ends. Wires are labeled per the
corresponding J1/P1 ECU pin.
©2014 Caterpillar
A 5 – CSA Class I Division 2 Certified Alternator Performance Curve
A 6 – ATEX Certified 35 Amp 24 Volt Alternator Performance Curves
©2014 Caterpillar
A7 – Bare Engine Ambient Capability

Rating A/C Mech. Gas Elec. Gas Mech. Elec.
Model Feature Code (Tier kW/hp @ rpm) Type Group Group Ambient Ambient
C07DW13 B 153/205 @2200 SCAC 2A 2C 37 45
C7
C07DW14 C 172/230 @2200 SCAC 2A 2C 34 45
C09DW21 D 254/340 @2200 SCAC 2A 2C 29 45
C09DW22 D 254/340 @2200 SCAC 2A 2C 45* 45
C9
C09DW19 D 254/340 @2200 REMAC 2A 2C 29 45
C09DW20 D 254/340 @2200 REMAC 2A 2C 45* 45
C15DW10/12/15
D 400/536 @1800-2000 REMAC 2A 2C n/a 60
C15DW17/20/22
C15DW11/13/16
D 400/536 @1800-2000 SCAC 2A 2C n/a 60
C15DW18/21/23
C15 C15DW09/14/19/30 D 400/536 @1800-2000 SCAC 2A 2C 50 60

D 400/536 @ 1800
C15DW24 SCAC
const. 2A 2C 50 60
Standby 360/483 @
C15DW25 SCAC
1500 2A 2C 50 60
Standby 400/536 @
C15DW26 SCAC
1800 2A 2C 50 60
C32DW47 A 597/800 @2100 SCAC 2A 2C 47 45
C32DW45 A 641/860 @2100 SCAC 2A 2C 35 45
C32
C32DW48 B 686/920 @2100 SCAC 2A 2C 30 45
C32DW46 D 826/1110 @2100 SCAC 2A 2C 47 45
The bare engine ambient capability shown may be changed by the addition of
insulative material or other technologies. Figures are for the engines as they
initially leave the engine production line without consideration of hardware or
materials added later. Cat HazPaks may have different ambient capability than the
underlying engines, please see HazPak literature on Powernet for details.
©2014 Caterpillar
LEBW0003-05 ©2014 Caterpillar Printed in U.S.A.
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APPLICATION AND INSTALLATION GUIDE

Petroleum Hazardous Location Engines

CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow,” the “Power

Hazardous Location Engines

2 Important Safety Information

The meaning of this safety alert symbol is as follows:

3 Hazardous Location Terms and Compliance

The electrical system meets the following ratings:

3.1.1 Class I Division 2 / Zone 2

A Class I Division 1 area is one where these same ignitable concentrations of

North American Area Classifications

3.1.1.1 NEC 500 and NEC 505 Gas Groups

3.1.2 ATEX Directive Compliance

3.1.2.1 Group II, 3G (Zone 2) Environments

Equipment Equipment Zone

3.1.2.3 Temperature Classes

4.1 ATEX Electrical Markings

These markings can be defined as:

4.2 ATEX Mechanical Markings

These markings can be defined as:

4.3 NEC 500 Markings

Classification: Class I Division 2 Groups ABCD

These markings can be defined as:

4.4 NEC 505 Markings

Classification: Class I Zone 2 Group IIC

These markings can be defined as:

Power at Lab Conditions

5.2 Non-Derated Engine Ratings

5.3 Constant Speed Ratings

All servicing of hazardous location engines must be done by a

6.1 Connecting Service Tools

6.2 Electrical Harness Connectors

6.2.2 C15 Connectors Figure 6.1

C15 Ampseal connector Figure 6.2

6.3 Battery Disconnect

No harnesses or electrical connections should be connected OR

7 Customer Installation Considerations

48 Un-switched Battery (+)

63 Un-switched Battery (-)

65 Un-switched Battery (-)

69 Un-switched Battery (-)

7.1.2 Termination of J1 harness

Liquid Tight Conduit

HAZARDOUS AREA SAFE AREA

Customer Interface Wiring Zone 2 and Safe Zone

Control Harness Incendive Wiring

Liquid Tight Liquid Tight

Liquid Tight Conduit

Customer Interface Wiring Zone 2 Only

• Conduit Gas Tight Seal

Customer Interface Kit Figure 7.4

7.1.3.1 Coolant Level Sensor

Cat ET Description J1939 Description Status SPN FMI

7.1.3.1.2 Coolant Level Monitoring Configuration

LOW COOLANT LEVEL MONITORING CONFIGURATION

7.1.3.1.3 Coolant Level Sensor Required Parts

Note: Coolant Level Sensor 331-7352 has 1/4-18 NPTF threads.

7.1.3.2 Aux Temperature Sensor

Cat ET Description J1939 Description Status SPN FMI

following additional actions when the monitoring system is configured to Derate

7.1.3.2.2 Auxiliary Temperature Monitoring Configuration

HIGH AUXILIARY TEMPERATURE MONITORING CONFIGURATION

7.1.3.3 Auxiliary Pressure Sensor

Cat ET Description J1939 Description Status SPN FMI